Spring cushion or mattress assembly and upholstery pad therefor



L. A. YOUNG 2,290,520

SPRING CUSHION OR MATTRESS ASSEMBLY AND UPI-IOLSTERY PAD THEREFOR July 21, 1942.

Filed Aug. 26, 1940 2 w M I Q INVENOR. BY Leo/74ml fingzy A ORNEYS.

Patented July 21, 1942 UNHT STATES SPRING CUSHION OR MATTRESS ASSEMBLY AND UPHOLSTERY PAD THEREFOR Claims.

This invention relates to improvements in spring cushion or mattress assemblies and upholstery pads therefor.

The main objects of this invention are:

First, to provide an improved spring assembly for mattresses, automobile seats and automobile backs and upholstery including a pad of fibrous material, the pad material being effectively bound together and reinforced so that while the pad is flexible in a plurality of directions, it constitutes an effective support element upon a spring assembly.

Second, to provide an upholstery pad for spring assemblies in which a mat of fibrous material is bound together and so supported that it does not become deformed or ruptured or the material become displaced from use.

Third, to provide an upholstery pad for spring assemblies which greatly facilitates upholstery operations and provides a superior product in the matter of cushioning qualities.

Third, to provide a structure having these advantages which is economical to produce.

Objects relating to details and economies of the invention will appear from the description to follow. The invention is defined and pointed out in the claims.

Preferred embodiments of the invention are illustrated in the accompanying drawing, in which:

Fig. 1 is a fragmentary plan view of a spring assembly of the automobile seat cushion type embodying the features of the invention, portions of the cover and padding being broken away to clearly show the application of the improved pad to a spring unit.

Fig. 2 is an enlarged fragmentary elevational view on a line corresponding to line 22 of Fig, 1.

Fig. 3 is a fragmentary perspective view of a pad embodying the features of the invention inverted from the position shown in Figs. 1 and 2.

Fig. 4 is an enlarged fragmentary elevational view showing a slightly modified form or embodiment of the invention.

Fig. 5 is a fragmentary sectional view showing another modified form or embodiment of the invention in which the reinforcing and supporting element is disposed centrally in the pad and constitutes means for retaining two layers of fibrous material together.

Fig. 6 is a perspective view of the reinforcing and supporting element of 5.

Fig. '7 is a perspective view of an element similar to that of Fig. 6 but of substantially less length.

Fig. 8 is a fragmentary elevational view illustrating another form of supporting and binding element and one step in the assembly thereof with the mat.

Fig. 9 is a fragmentary sectional view of the completed mat in which the reinforcing element is introduced as a preliminary step in the manufacture of the mat is shown in Fig. 8.

There is a considerable trend at the present time in the manufacture of cushions generally, the making of mattresses or motor vehicle cushions and the like, toward soft or yielding surfaces and such structures where mats or pads of fibrous material are largely used are likely to become displaced in use or worked down between the springs of the spring assembly. Various means have been resorted to, to overcome this tendency, but so far as I am aware they are all open to certain objections, Various fibrous materials are used, as cotton, usually a very cheap grade of cotton, various waste materials in fiber form, sisal, and the like.

By my improvements presently to be described, I obtain the desired soft or yielding qualities using a bat-like mat of inexpensive, unwoven material and at the same time a structure which is very durable and the pressure thereon is largely localized as distinguished from being extended over the entire or over a wide portion of the spring assembly.

In the embodiment illustrated in the accompanying drawing, I illustrate in Figs. 1 and 2 an automobile seat cushion structure comprising a plurality of coiled springs 1 arranged in pockets 2, the springs being arranged in rows, the adjacent springs of the rows being connected by clips 3 and their border springs being connected by clips G to the top frame 5. I have not illustrated the bottom frame structure as that forms no part of my present invention.

The upholstery covering is indicated at 6 and this may be attached by suitable means not deemed necessary to here illustrate.

My improved upholstery pad, as illustrated in Figs. 1, 2 and 3 comprises a mat of fibrous material I, this mat, in this embodiment, being of felted cotton or other suitable material and I have attempted to illustrate the same in felted condition in Figs. 2 and 3. This mat of felted fibrous material is bound together and reinforced by the reinforcing elements 8 formed of strands of wire, the ends of these strands of wire being passed through the felted fibrous material and being clamped or clinched thereon as shown at 9.

These elements 8 are of substantial length and are arranged in parallel rows with the reinforcing elements of the rows in substantially spaced aligned relation. The reinforcing elements of adjacent rows are arranged in alternating or staggered relation, the spaces in the rows being such that the alternating of the staggered elements causes the overlapping of the elements of adjacent rows. However, the spacing of the elements and also the spacing in the rows is such that there is a substantial flexibility or capacity for flexing in a plurality of directions.

These reinforcing and supporting elements 8, being clinched or clamped to the fibrous mat material, serve as reinforcing elements therefor and also as supports for the mat when the mat is arranged upon a spring assembly, as shown in Figs. 1 and 2.

The elements 8 are preferably of such length as to bridge the ends of the spring or the spaces between the rows of springs, or between the fasteners thereof, so that in use the material constituting the mat or pad is bound together and supported throughout and is very unlikely to be pulled out of shape as a result of concentrated weight, for example, of a person sitting upon the cushion or to work down between the springs as a result of the concentrated load.

I preferably provide border elements indicated at "3 in Fig. 1, these being arranged in staggered overlapping relation transversely of the elements 8 and in spaced relation to the side edges of the pad. They are of particular importance at this point in reinforcing the edge of the pad as well as to supplement the elements 8.

In the embodiment shown in Fig. 4, the elements H are somewhat shorter than those shown in Figs. 1 and 3 but they should be of substantial length in order to perform the functions of supports as well as binding together and reinforcing substantial portions of the fibrous material. While I have illustrated in Figs. 1, 2 and 3 fibrous material such as cotton and substantially felted, I illustrate in Fig. 4 fibrous material l2 of sisal and this does not have any considerable felting capacity.

In Fig. 5 I show a modified form of the invention in which the fibrous material is in the form of two layers of sisal I3 bound together and reinforced by the elongated reinforcing and supporting elements M which are formed of strip of sheet metal having prongs l5 struck out from the edge thereof, these members I4 being arranged between the layers of mat material I3 and the prongs clinched down on the material as indicated at 16, thus binding the layers of material together very effectively and at the same time providing a supporting means for the purpose described.

In Fig. '7, the reinforcing and supporting elements H are of the same type as shown in Fig. 6 but much shorter. These would be arranged in rows in staggered relation as shown in Figs. 1, 2 and 3.

In Figs. 8 and 9, I illustrate another embodiment of the invention in which the wire strands l8 are rove through the pad material IS, the fiuting or pleat-like offsets being formed in the material to receive the strands. After the strands are inserted, the offsets 29 are formed in the strands so that there are alternating reaches 2| on the opposite sides of the pad of material. The offsetting serves to retain the strands and when offset the strands effectively bind and reinforce the mat material.

The embodiments of the invention previously described are now preferred by me on account of the simplicity and economy in the forming of the elements and in the assembling thereof with the mat material. Machines something of the nature of the box fastener machines and stapling machines but of suitable size and arrangement of stapling heads may be used very effectively.

Structures embodying my invention have a wide range of utility, being highly desirable for use in mattresses, automobile cushions, and automobile upholstery generally, and in various furniture cushions and upholstery. My invention enables the use of a very low grade of material for instance, cotton and cotton waste and other waste, at the same time it is bound together and reinforced so that it is capable of withstanding strains such as it is subjected to in the uses I have indicated. Sisal has very little, if any, real felting characteristics but my invention enables the production of very satisfactory pads of such material and the pads are much stronger and durable as compared to the ordinary unreinforced sisal pads or pads of sisal or like material or such pads in combination with some supporting fabric.

I have not attempted to illustrate or describe various other embodiments which I contemplate as it is believed that the disclosure made will enable those skilled in the art to embody or adapt my improvements as may be desired.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent is:

1. An upholstery pad for a spring assembly including a plurality of body springs comprising a mat of felted fibrous material of substantial thickness and of substantially uniform thickness throughout, and a plurality of parallel rows of elongated reinforcing and supporting elements of substantial length having their ends disposed through and clinched upon said fibrous mat material, the elements being aligned and substantially spaced in the rows, the spacing of the elements in the rows approximating the length of the elements, the elements of adjacent rows being arranged in staggered relation and with their ends in overlapping relation relative to the ends of the elements of adjacent rows, there being spaced border elements disposed transversely of the elements of the rows and in spaced'relation thereto and parallel to but spaced inwardly from the side edges of the mat.

2. An upholstery pad for a spring assembly including a plurality of body springs comprising a mat of felted unwoven, bat-like, fibrous material of substantial thickness and of substantially uniform thickness throughout, and a plurality of parallel rows of elongated reinforcing and supporting elements of substantial length having their ends disposed through and clinched upon said fibrous mat material, the elements being aligned and substantially spaced in the rows, the spacing of the elements in the rows approximating the length of the elements, the elements of adjacent rows being arranged in staggered relation and with their ends in overlapping relation relative to the ends of the elements of adjacent rows.

3. An upholstery pad comprising a mat of fibrous material of substantial thickness, and a plurality of parallel rows of elongated reinforcing and supporting elements of substantial length having portions thereof clampingly engaging said fibrous mat material, there being a pluralit of the elements in the rows disposed in spaced aligned relation, the elements of adjacent rows being arranged in staggered relation, there being spaced elongated reinforcing elements disposed transversely of the elements of the rows and in spaced relation thereto and to adjacent edges of the mat.

4. An upholsterypad comprising a mat of fibrous material of substantial thickness, and a plurality of parallel rows of elongated reinforcing and supporting elements of substantial length having portions thereof clampingly engaging said fibrous mat material, there being a plurality of the elements in the rows disposed in spaced aligned relation, the elements of adjacent rows being arranged in staggered relation.

5. An upholstery pad comprising a mat of fibrous material, and a plurality of parallel rows of wire reinforcing and supporting elements disposed in spaced aligned relation in the rows and with the reinforcing elements of adjacent rows in staggered relation, portions of the elements being clinched in the fibrous material, the length of the elements and the spacing thereof in the rows and the spacing of the rows being such as to permit flexing of the pad in a plurality of directions, the elements constituting reinforcing and binding elements for the mat of fibrous material and supports therefor when the pad is assembled with supporting parts such as a spring assembly.

6. An upholstery pad comprising a mat of unwoven, batt-like, fibrous material, and a plurality of rows of elongated strip-like reinforcing and supporting elements of metal disposed in penetrating laterally spaced relation and being in clamping engagement with the fibrous material, the spacing of the elements in each row and of the elements of the adjacent rows being such as to longitudinally overlap the respective elements in adjacent rows to permit flexing of the pad in a plurality of directions, the elements constituting reinforcing and binding elements for the mat of fibrous material and supports therefor when the pad is assembled for use with supporting parts such as a spring assembly.

'7 An upholstery pad for a cushion spring assembly comprising a plurality of body springs, said pad comprising a mat of fibrous material, and

a plurality of parallel rows of wire reinforcing and supporting strands disposed in alignment in the rows and with the reinforcing strands of adjacent rows in staggered relation, the ends of the strands being clinched in the fibrous mat material, the length of the strands and the spacing thereof in the rows and the spacing of the rows being such as to permit flexing of the pad in a plurality of directions, the strands constituting reinforcing and binding elements for the mat of fibrous material and supports for the same on the spring assembly.

8. An upholstery pad for a cushion spring assembly comprising a plurality of coiled body springs, said pad comprising a mat of fibrous material, and a plurality of parallel rows of reinforcing and supporting elements disposed in alignment in the rows and with the reinforcing elements of adjacent rows in staggered relation, the elements being in binding engagement with the fibrous mat material, the length of the elements and the spacing thereof in the rows and the spacing of the rows being such as to permit flexing of the pad in a plurality of directions, the elements constituting reinforcing and binding elements for the mat of fibrous material and supporting the same against collapsing within or between the springs of the spring assembly.

9. An upholstery pad comprising a mat of felted fibrous material of substantial thickness, and a plurality of elongated reinforcing elements of substantial length in binding and retaining engagement with the mat material, said elements being arranged in parallel rows and spaced in the rows, the elements of adjacent rows being arranged in staggered relation.

10. An upholstery pad of the class described comprising superimposed layers of fibrous material, each of substantial thickness, and a plurality of elongated reinforcing and supporting elements arranged between the layers and disposed in parallel rows and spaced in the rows, the elements of adjacent rows being disposed in staggered overlapping relation, the elements having oppositely directed prongs clinched in both layers whereby said elements bind the layers together and bind the fibers of the layers and constitute supports when the pad is arranged on supporting parts such as a spring assembly.

LEONARD A. YOUNG. 

